Abstract:

Heavy off-road vehicle suspension systems face unique challenges. The ride comfort versus handling compromise in these vehicles has
been frequently investigated using mathematical optimisation. Further challenges exist due to the large variations in vehicle sprung mass.
A passive suspension system can only provide optimal isolation at a single payload. The designer of such a suspension system must therefore
make a compromise between designing for a fully-laden or unladen payload state. This work deals with suspension optimisation for
vehicle structural life. The paper mainly addresses two questions: (1) What are the suspension characteristics required to ensure optimal
isolation of the vehicle structure from road loads? and (2) If such optimal suspension characteristics can be found, how sensitive are they
to changes in vehicle payload? The study aims to answer these questions by examining a Land Rover Defender 110 as test vehicle. An
experimentally validated non-linear seven degree-of-freedom mathematical model of the test vehicle is constructed for the use in sensitivity
studies. Mathematical optimisation is performed using the model in order to find the suspension characteristics for optimal structural
life for the vehicle under consideration. Sensitivity studies are conducted to determine the robustness of the optimal characteristics
and their sensitivity to vehicle payload variation. Recommendations are made for suspension characteristic selection for optimal structural
life.